Basic fire-brick lining.



UNITED STATES PATENT OFFICE.

SPENCER B. NEWBERRY, OF BAYBRIDGE, OHIO.

BASIC FIRE-BRICK LINING.

: character hereinafter fully set forth.

Heretofore clinker brick have been pro duced by mixing Portland cementclinker and ground cement with water, and molding into the desiredshape, but as heretofore made they have had the serious drawback thatthe entire mass of the bricks is not transformed by the action of thekiln, so that, although the face of the mass becomes hardened by theaction of the heat, there is a zone of weakness back of this face wh chcauses the face to scale otl, destroying the efficiency of the lining;while, further, the mass of the material after lon continued heating andcooling down, disintegrates, breaking up in the form of dust, and istherefore lost when the kiln is allowed to become cool. I have foundthat these de fccts may be overcome by subjecting the proper compositionto such a heat and for such a length of time as to practically transformthe entire mass, driving off all of the combined water of the cementthroughout the mass and forming a dense, compact block of uniformcharacter throughout, and that said block, when used for lining in akiln, will perfectly resist the action of the lime of the charge andremain firm and durable through long periods of service, without scalingand without disintegrating on coolmg.

In carrying my invention into practice I take cement clinker, formed bycalcining Portland or natural cement raw material, and pulverize thesame, reducing it to a coarse powder, preferably such as will passthrough a one-tenth or a one-twentieth inch screen. In this pulverizingoperation a portion of finer material or dust will be formed which willcause the mixture to set well when water is added. This pulverizedclinker is then mixed with the proper amount of water to Specificationof Letters Patent:

Application filed March 28, 1908.

Patented July 13, 1909.

Serial No. 423,908.

form a dough or body and is then tamped into molds of suitable size andshape. After setting or hardening for twenty-foul"hours or more theblocks are then thoroughly dried and subjected in a suitable kiln(preferably of the down-draft type, such as used in burning ordinaryfire-brick) to a sintering heat; that is, a bright orange heat for fromtwelve to forty eight hours, or longer if necessary, the heat beingcontinued for such a length of time as to transform the entire mass.After being thus burned the bricks are cooled and are then ready to beused in lining cement furnaces, or limekilns or other furnaces, and toform a durable basic lining free from all tendency to flux or corrodeunder the action of the material being treated and which will not scaleand will not disintegrate when the furnace is cooled. In laying up thelining I prefer to make use of a Portland cement mixture as a mortar,mak ing the joint as close as possible.

\Vhile in many cases blocks of the proper character may be formed bythus burning the clinker brick alone, I have found that a greatadvantage may be secured by adding to the coarsely ground clinker asuitable proportion of lime, and especially of dolomitic or magnesiumlime. Magnesian lime is preferable for the reason that a much largerquantity can be used than of pure lime, inasmuch as more than a certainpercentage of pure lime results in a tendency to,air-slack anddisintegrate on storage, while magnesian lime has no such injuriouseffect, and at'the same time acts similarly to lime in increasing thebasic character of the resulting lining, and overcoming the tendency tofall to dust on cooling after long-continued heating. In thus making.use of lime or magnesian lime in making clinker brick, I have foundthat good results ensue from the addition to theclinker brick mixture offrom five to twenty per cent. of the lime or magnesian lime, the mostadvantageous quantity can be used depending on the composition of theclinker and of the lime employed, a clinker high in lime requiring asmaller additionthan one containing a lower proportion of llme. The limeor magnesian lime added may be in the form of commercial slaked orhydrate lime, or of quick-lime slaked to a paste before ,mixing with theclinker. In the process of burning the blocks, the lime or magnesianlime is absorbed by and combines wlth the clinker, increasing thestrength and density of the blocks and making the mass slightly morebasic than the charge of the cement kiln, thus increasing its resistanceto fiuxing or fusing and overcoming its tendency to burned so as to befreed from water and ofa uniform character throughout.

2. A basic brick consisting of granulated hydraulic cement clinker andan alkaline earth molded and burned so as to be freed from water and ofa uniform character throughout.

3. A basic brick consisting of-granulated hydraulic cement clinker andlime molded and burned so as to be freed from water and of a uniformcharactei throughout.

4. A basic brick consisting of hydraulic cement clinker, lime andmagnesia, molded and burned so as to be freed from Water and of auniform character throughout.

5. The method of manufacturing a refractory material which consists ingranulating hydraulic cement clinker, mixing it with water into a paste,and burning the mixture until it is freed "from water, sinteredtogether, and is of a uniform character throughout.

6. The method of manufacturing a refractory material, which consists ingranulating hydraulic cement clinker, mixing it with an alkaline earthand water into a paste, and burning the mixture until it is freed fromWater and of a uniform character throughout.

7. The method of manufacturing a refractory material, which consists ingranulating hydraulic cement clinker, mixing 'it with lime and waterinto a paste, and burning the mixture until it is freed from water andof a uniform character throughout.

8. The method of manufacturinga refractory material, which consists ingranulating hydraulic cement clinker, mixing it with lime, magnesia andwater into a paste, and burning the mixture until it is freed from waterand of a uniform character throughout.

9. The method of manufacturin a refractory brick, which consists ingranu ating hydraulic cement clinker, mixing it with water into a paste,molding it into a brick, drying it, and burning it until it is freedfrom water and is of a uniform character throughout.

10. The method of manufacturing a refractory brick, which consists ingranu1ating hydraulic. cement clinker, mixing it with an alkaline earthand water into a paste, molding it into a brick, drying it, and burningit until it is freed from water and is of a uniform characterthroughout.

In testimony whereof I afiix my signature in presence of two Witnesses.

SPENCEEB. NEWBERRY. Witnesses:

WILLIAM L. TRos'r, BERT MARTIN.

